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Methods and apparatus for spray forming, atomization and heat transfer |
| 6772961 |
Methods and apparatus for spray forming, atomization and heat transfer
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| Patent Drawings: | |
| Inventor: |
Forbes Jones, et al. |
| Date Issued: |
August 10, 2004 |
| Application: |
09/882,248 |
| Filed: |
June 18, 2001 |
| Inventors: |
Conrad; Helmut Gerhard (Oshawa, CA) Conrad; Wayne (Hampton, CA) Forbes Jones; Robin M. (Charlotte, NC) Kennedy; Richard L. (Monroe, NC) Phillips; Andrew Richard Henry (Courtice, CA) Phillips; Richard Stanley (Courtice, CA) Szylowiec; Ted (Hampton, CA)
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| Assignee: |
ATI Properties, Inc. (Albany, OR) |
| Primary Examiner: |
Hwu; Davis |
| Assistant Examiner: |
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| Attorney Or Agent: |
Hale and Dorr LLP |
| U.S. Class: |
239/132; 239/132.1; 239/3; 239/690; 239/79 |
| Field Of Search: |
; 239/79; 239/3; 239/8; 239/10; 239/13; 239/690; 239/691; 239/706; 239/128; 239/132; 239/131.1; 239/131.3; 239/131.5; 239/398; 427/450; 427/419.2; 427/451; 427/453; 427/454 |
| International Class: |
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| U.S Patent Documents: |
4062700; 4264641; 4441542; 4689074; 4762553; 4769064; 4788016; 4801411; 4842170; 5104634; 5240067; 5368897; 5377961; 5722479; 5810066; 5894980; 6103182; 6168666; 6562099 |
| Foreign Patent Documents: |
3-36205 |
| Other References: |
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| Abstract: |
The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention. |
| Claim: |
What is claimed is:
1. An apparatus comprising: a dispensing means; a collecting means; a means for directing one or more molten particles from the dispensing means to the collecting meanscomprising at least one of an electrostatic field and an electromagnetic field; and a means for transferring heat from the collecting means comprising a means for generating a non-equilibrium plasma.
2. The apparatus of claim 1, further comprising at least one magnetic coil.
3. The apparatus of claim 1, further comprising a means for charging the molten particles.
4. The apparatus of claim 3, wherein the means for charging the molten particles comprises a thermionic emission source or a tribocharging device.
5. The apparatus of claim 1, wherein the dispensing means comprises a gas atomizer.
6. The apparatus of claim 1, further comprising a means for transferring heat from the molten particles.
7. The apparatus of claim 6, wherein the means for transferring heat from the molten particles comprises gas conduction or convection.
8. The apparatus of claim 6, wherein the means for transferring heat from the molten particles comprises a non-equilibrium plasma.
9. The apparatus of claim 1, further comprising a means for transferring heat from the molten particles comprising: a first heat sink, wherein the first heat sink is electrically charged or held at a potential; and a means for transferring heatfrom the molten particles to the first heat sink comprising a means for generating a non-equilibrium plasma.
10. The apparatus of claim 9, wherein the non-equilibrium plasma is a glow discharge or a cold corona discharge.
11. The apparatus of claim 1, further comprising a means for expelling the molten particles through at least one orifice in the dispensing means; and a means for applying a rapid electrostatic charge to the molten particles.
12. The apparatus of claim 11, wherein the means for expelling the molten particles through the at least one orifice comprises a mechanical or electromechanical actuator.
13. The apparatus of claim 11, wherein the means for expelling the molten particles through the at least one orifice comprises a pressure means that produces a pressure one the inside of the dispensing means that is greater than the pressure onthe outside of the dispensing means.
14. The apparatus of claim 13, wherein the pressure means causes interrupted flow of the molten particles from the dispensing means.
15. The apparatus of claim 11, wherein the rapid electrostatic charge comprises an arc discharge or an electron beam.
16. The apparatus of claim 1, further comprising: a chamber enclosing at least part of the dispensing means, collecting means and means for directing; and means for providing vacuum to the chamber.
17. The apparatus of claim 1, wherein the one or more molten particles are metallic.
18. A spray forming method comprising: directing one or more molten particles from a dispensing means to a collecting means by producing at least one of an electrostatic field or an electromagnetic field between the dispensing means and thecollecting means; and transferring heat from the molten particles using a non-equilibrium plasma, wherein transferring heat from the molten particles comprises producing a non-equilibrium plasma that transfers heat from the molten particles to a firstheat sink, wherein the first heat sink is electrically charged or held at a potential.
19. The method of claim 18, comprising producing the electromagnetic field with at least one magnetic coil.
20. The method of claim 18, further comprising charging the molten particles.
21. The method of claim 20, comprising charging the molten particles using a thermionic emission source or a tribocharging device.
22. The method of claim 18, wherein the dispensing means is a gas atomizer.
23. The method of claim 18, further comprising producing a second electromagnetic field.
24. The method of claim 18, further comprising transferring heat from the collecting means.
25. The method of claim 24, comprising transferring heat from the collecting means using a non-equilibrium plasma.
26. The method of claim 18, comprising applying a rapid electrostatic charge to the molten particles, wherein the rapid electrostatic charge causes the molten particles to form at least one smaller molten particles.
27. The method of claim 26, wherein the rapid electrostatic charge is an arc discharge or an electron beam.
28. The method of claim 18, wherein the non-equilibrium plasma is a glow discharge or a cold corona discharge.
29. The method of claim 18, further comprising: performing the acts of directing one or more molten particles and transferring heat in vacuum.
30. The method of claim 18, wherein the one or more molten particles are metallic.
31. An apparatus comprising: a melt chamber comprising at least one orifice; a means for forcing a molten material through the at least one orifice in the melt chamber; a means for applying a rapid electrostatic charge to the molten material; and a means for transferring heat from the collecting means comprising a means for generating a non-equilibrium plasma.
32. The apparatus of claim 31, wherein the rapid electrostatic charge is an arc discharge or an electron beam.
33. The apparatus of claim 31, further comprising a means for cooling the molten material.
34. The apparatus of claim 33, wherein the means for cooling the molten material comprises: a first heat sink, wherein the first heat sink is electrically charged or held at a potential; and a means for transferring heat from the moltenmaterial to the first heat sink comprising a means for generating a non-equilibrium plasma.
35. The apparatus of claim 34, wherein the non-equilibrium plasma is a glow discharge or a cold corona discharge.
36. An apparatus comprising: a dispensing means; a collecting means; a means for directing one or more molten particles from the dispensing means to the collecting means comprising at least one of an electrostatic field or an electromagneticfield; a means for transferring heat from the collecting means comprising a means for generating a non-equilibrium plasma; and a means for transferring heat from the molten particles, wherein the means for transferring heat from the molten particlescomprises gas conduction or convection, and wherein the means for transferring heat from the molten particles comprises a non-equilibrium plasma.
37. The apparatus of claim 36, further comprising; a vacuum chamber enclosing at least the means for directing.
38. The apparatus for claim 36, wherein the means for directing further comprises: a means for atomizing the molten particles.
39. The apparatus for claim 36, wherein the molten particles are metallic.
40. An apparatus comprising: a dispensing means; a collecting means; a means for directing one or more molten particles from the dispensing means to the collecting means comprising at least one of an electrostatic field or an electromagneticfield; a means for transferring heat from the collecting means comprising a means for generating a non-equilibrium plasma; a means for expelling the molten particles through at least one orifice in the dispensing means; a means for applying a rapidelectrostatic charge to the molten particles, wherein the means for expelling the molten particles through the at least one orifice comprises a mechanical or electromechanical actuator.
41. The apparatus of claim 40, further comprising; a vacuum chamber enclosing at least the means for directing.
42. The apparatus for claim 40, wherein the means for directing further comprises: a means for atomizing the molten particles.
43. The apparatus for claim 40, wherein the molten particles are metallic.
44. A spray forming method comprising: directing one or more molten particles from a dispensing means to a collecting means by producing at least one of an electrostatic field or an electromagnetic field between the dispensing means and thecollecting means; and transferring heat from the molten particles using a non-equilibrium plasma, wherein transferring heat from the molten particles comprises producing a non-equilibrium plasma that transfers heat from the molten particles to a firstheat sink, wherein the first heat sink is electrically charged or held at a potential.
45. The method of claim 44, wherein the non-equilibrium plasma is a glow discharge or a cold corona discharge.
46. The method of claim 44, further comprising atomizing the molten particles.
47. The method of claim 44, further comprising performing the act of directing the molten particles in vacuum.
48. The method of claim 44, wherein the molten particles are metallic.
49. An apparatus comprising: a melt chamber comprising at least one orifice; a means for forcing a molten material through the at least one orifice in the melt chamber; a means for applying a rapid electrostatic charge to the molten material; and a means for transferring heat from the collecting means comprising a means for generating a non-equilibrium plasma, wherein the means for cooling the molten material comprises: a first heat sink, wherein the first heat sink is electrically charged orheld at a potential; and a means for transferring heat from the molten material to the first heat sink comprising a means for generating a non-equilibrium plasma.
50. The apparatus of claim 49, wherein the non-equilibrium plasma is a glow discharge or a cold corona discharge.
51. The apparatus of claim 49, further comprising; a vacuum chamber enclosing at least the means for directing.
52. The apparatus for claim 49, wherein the means for directing further comprises: a means for atomizing the molten material.
53. The apparatus for claim 49, wherein the molten material is metallic.
54. An apparatus comprising: a dispenser configured to release one or more molten particles; a collector configured to receive the one or more molten particles; one or more electric coils configured to create at least one of an electrostaticfield and electromagnetic field for directing the one or more molten particles from the dispenser to the collector; and one or more electrodes configured to generate a non-equilibrium plasma for transferring heat from the collector.
55. The apparatus of claim 54, futher comprising: a chamber enclosing at least part of the dispenser, collector, one or more electric coils and one or more electrodes; a vacuum source coupled to the chamber for providing vacuum to the chamber.
56. The apparatus of claim 54, wherein the one or more molten particles are metallic.
57. The apparatus of claim 54, wherein the collector is a solid preform.
58. The apparatus of claim 54, wherein the collector is a container configured to receive the one or more molten particles.
59. The apparatus of claim 54, wherein the dispenser further comprises: a pair of opposing electrodes.
60. The apparatus of claim 54, wherein the dispenser further comprises: one or more electron beam sources.
61. The apparatus of claim 60, wherein the dispenser further comprises: a water-cooled copper cold hearth.
62. The apparatus of claim 54, wherein the dispenser further comprises: means for melting ESR or VAR.
63. The apparatus of claim 54, further comprising: an atomizer configured to atomize the one or more molten particles.
64. The apparatus of claim 54, further comprising: an electronic beam configured to atomize the one or more molten particles.
65. A method comprising: releasing molten particles from a source; electrostatically charging the molten particles; receiving the charged molten particles to a collector; creating at least one of an electrostatic field and electromagneticfield for directing the charged molten particles to the collector; and transferring heat from the collector using one or more electrodes configured to generate a non-equilibrium plasma.
66. The method of claim 65, further comprising: performing the acts of releasing, charging, receiving and creating in vacuum.
67. The method of claim 65, wherein themolten particles are metallic.
68. The method of claim 65, wherein the collector is a solid preform.
69. The method of claim 65, wherein the collector is a container configured to receive the molten particles.
70. The method of claim 65, wherein the act of charging comprises: flowing the molten particles through a pair of opposing electrodes.
71. The method of claim 65, wherein using one or more electron beam sources in releasing the molten particles.
72. The method of claim 65, wherein using a water-cooled copper cold hearth in releasing the molten particles.
73. The method of claim 65, wherein melting ESR or VAR in releasing the molten particles.
74. The method of claim 65, further comprising: atomizing the charged molten particles.
75. The method of claim 74, wherein using an electronic beam in atomizing the charged molten particles.
76. A spray forming method comprising: directing one or more molten particles from a dispensing means to a collecting means by producing at least one of an electrostatic field or an electromagnetic field between the dispensing means and thecollecting means; applying a rapid electrostatic charge to the molten particles using an electron beam; and transferring heat from the molten particles using a non-equilibrium plasma, wherein transferring heat from the molten particles comprisesproducing a non-equilibrium plasma that transfers heat from the molten particles to a first heat sink, wherein the first heat sink is electrically charged or held at a potential.
77. The method of claim 76, further comprising performing the act of directing the molten particles in vacuum.
78. An apparatus comprising: a dispenser configured to release one or more molten particles using an electron beam; a collector configured to receive the one or more molten particles; one or more electric coils configured to create at leastone of an electrostatic field and electromagnetic field for directing the one or more molten particles from the dispenser to the collector; and one or more electrodes configured to generate a non-equilibrium plasma for transferring heat from thecollector.
79. The apparatus of claim 78, further comprising a vacuum chamber enclosing at least the collector. |
| Description: |
FIELD OF THE INVENTION
The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for heattransfer using non-equilibrium plasmas and for atomization.
BACKGROUND OF THE INVENTION
Spray forming is a process by which a stream of molten metal is atomized by a gas stream impinging upon it. The resulting atomized droplets are then directed to a target by the gas stream, or the resulting atomized droplets are cooled to form apowder. Producing powders by typical prior spray forming methods results in a yield loss of 10-15%, and much of the loss is associated with powder being trapped in various areas of the apparatus rather than being delivered to the collection vesselduring the process. In producing solid workpieces, known as preforms, typical prior spray forming methods result in a yield loss of 25-40%, and a significant portion of the loss is usually caused by over-spray and particles bouncing off the surface dueto their angular impact relative to the normal of the preform surface. Various methods have been described to recover and reuse overspray powder, such as, for example, U.S. Pat. No. 5,649,993, but these are not wholly satisfactory.
Because many powders and preforms are susceptible to damage to their chemical structure by air and oxygen, they are often produced in a shield gas environment of nitrogen or argon. The flow of shield gas, however, must be turned off to allowworkers to enter the chamber for cleanup, changeover and maintenance. Thus, any powder or preform remaining in the chamber becomes contaminated and unusable when air and oxygen enter the spray forming apparatus after the flow of shield gas is turnedoff.
Previously, gas streams or jets have been used to direct the path of the particles involved in the spray forming process. The gas streams typically consist of argon or nitrogen as the means of directing the particles, and heat is removed fromthe workpiece through conduction or convection.
Current processes for making powder metal products, particularly in materials used for critical aerospace applications, use a conventional gas atomizing process. In this process, high-pressure gas is directed at a molten metal stream to break itinto smaller droplets. The droplets solidify as powder. For critical applications, the resultant powder is then blended with batches of powder from other small melts. The blend is screened to a small mesh size (325 mesh), canned and consolidated byextrusion into product suitable for manufacture into an aircraft component. This method of manufacture is not efficient because several small melts are required for blending, melts are made in conventional ceramic lined furnaces and hence result inoxide contamination, several powder handling operations offer opportunity for contamination, and many steps in the process make the production operation costly.
Heat transfer using non-equilibrium plasmas has heretofore been poorly understood and often incorrectly or inefficiently applied. There is a need in the art for methods and apparatus that improve the yield and quality of powders and preformsproduced by spray forming. The present invention is directed to these, as well as other, important ends.
SUMMARY OF THE INVENTION
The present invention overcomes the limitations of the conventional powder process by permitting a significantly larger melt to be manufactured to powder, thereby eliminating the blending steps. They also are melted and atomized in a ceramiclesssystem, thereby minimizing the contamination from the furnace linings. They are atomized in vacuum, thereby eliminating the need for screening and handling. They can either be containerized and sealed in a vacuum or rapidly solidified to form a solidpreform in vacuum, thereby eliminating sources of handling and hence possible contamination. Finally, the present invention will have considerably fewer handling steps than conventional powder making, and thus will be more cost effective.
In one embodiment, the present invention describes apparatus comprising dispensing means, collecting means, and means for directing molten particles from the dispensing means to the collecting means comprising an electrostatic field and/or anelectromagnetic field. Optionally, the apparatus may further comprise atomization apparatus and/or non-equilibrium heat transfer apparatus.
In another embodiment, the present invention describes spray forming methods comprising directing molten particles from dispensing means to collecting means by producing an electrostatic field and/or electromagnetic field between the dispensingmeans and the collecting means. Optionally, the apparatus may further comprise atomization apparatus and/or non-equilibrium heat transfer apparatus.
In another embodiment, the present invention is directed to apparatus comprising a melt chamber that comprises at least one orifice; a means for expelling a molten material through the at least one orifice in the melt chamber; and a means forapplying a rapid electrostatic charge to the molten material. Preferably, the means for forcing the molten material through the at least one orifice in the melt chamber is a mechanical or electromechanical actuator or a pressure means. In a preferredembodiment, the apparatus further comprises a means for cooling the molten particle. Preferably, the means for cooling the molten particle comprises a means for generating a non-equilibrium plasma.
In another embodiment, the present invention describes methods for forming particles comprising producing a first molten particle; and applying a rapid electrostatic charge to the first molten particle, wherein the rapid electrostatic chargecauses the first molten particle to form at least one smaller second particle. Preferably, the first molten particle is expelled through at least one orifice in the melt chamber via mechanical means or by a pressure means. In a preferred embodiment,the at least one smaller second molten particle is cooled, preferably by a non-equilibrium plasma.
In another embodiment, the present invention is directed to apparatus for transferring heat between a heat-transfer device and a workpiece comprising the heat-transfer device, wherein the heat-transfer device is electrically charged or held at apotential; the workpiece, wherein the workpiece is mechanically separate from the heat-transfer device; and means for transferring heat between the workpiece and the heat-transfer device comprising a means for generating a non-equilibrium plasma. Theheat-transfer device can be either a heat sink or a heat source.
In yet another embodiment, the present invention is directed to methods of transferring heat between a heat-transfer device and a workpiece comprising producing a non-equilibrium plasma capable of transferring heat between the heat-transferdevice and the workpiece, wherein the heat-transfer device is electrically charged or held at a potential, and wherein the heat-transfer device is mechanically separate from the workpiece. The heat-transfer device can be either a heat sink or a heatsource.
Accordingly, in various embodiments, non-equilibrium plasmas are advantageously employed to effect optimal heat transfer, and the non-equilibrium plasma must act with a heat sink/source that has a thermal conductivity capable of removing thedesired quantity of heat. While two or more electrodes have been used in the past to produce a plasma in a region of high heat, such as a weld zone, so that the plasma would serve to conduct heat outward from the weld zone, thereby increasing thesurface area for heat, embodiments of the present invention are directed to the discovery that a non-equilibrium plasma may be used to introduce heat into a workpiece as well as from a workpiece. It has further been surprisingly discovered that underthe correct conditions a non-equilibrium plasma can be used to efficiently transfer heat in a vacuum.
The novel methods of the present invention are particularly useful in preparing any metal article, such as articles for gas turbine engines, including, for example, airfoils, blades, discs and blisks.
Accordingly, in one aspect, there is provided according to the present invention an apparatus comprising: a dispensing means; a collecting means; and a means for directing a molten particle from the dispensing means to the collecting meanscomprising at least one of an electrostatic field or an electromagnetic field. In another aspect is provided the apparatus described above, wherein the means for directing the molten particles from the dispensing means to the collecting means comprisesan electrostatic field or an electromagnetic field. The apparatus may further comprise at least one magnetic coil, and may also further comprise a means for charging the molten particles. In one embodiment, the means for charging the molten particlesmay comprise a thermionic emission source or a tribocharging device. The dispensing means of the apparatus may be a gas atomizer, and may further comprise a means for transferring heat from the molten particles. The means for transferring heat from themolten particles may comprise gas conduction and/or convection and/or a non-equilibrium plasma.
In another aspect, there is provided according to the present invention an apparatus comprising: a dispensing means; a collecting means; and a means for directing a molten particle from the dispensing means to the collecting means comprising atleast one of an electrostatic field or an electromagnetic field, and further comprising a means for transferring heat from the collecting means. The means for transferring heat from the collecting means may comprise a means for generating anon-equilibrium plasma. In a particular aspect, the means for transferring heat from the molten particles comprises a first heat sink, wherein the first heat sink is electrically charged or held at a potential; and a means for transferring heat from themolten particles to the first heat sink comprising a means for generating a non-equilibrium plasma. The non-equilibrium plasma may be a glow discharge or a cold corona discharge.
In another aspect, there is provided according to the present invention an apparatus comprising: a dispensing means; a collecting means; and a means for directing a molten particle from the dispensing means to the collecting means comprising atleast one of an electrostatic field or an electromagnetic field, and further comprising a means for expelling the molten particle through at least one orifice in the dispensing means; and a means for applying a rapid electrostatic charge to the moltenmaterial. The means for expelling the molten particle through the at least one orifice may comprise a mechanical or electromechanical actuator. In one aspect, the means for expelling the molten particle through the at least one orifice may be apressure means that produces a pressure in the dispensing means that is greater than the pressure on the outside of the dispensing means. The pressure means may cause interrupted flow of the molten particle from the dispensing means. The rapidelectrostatic charge may be an arc discharge or an electron beam.
In another aspect, the present invention provides for a spray forming method comprising directing molten particles from a dispensing means to a collecting means by producing at least one of an electrostatic field or an electromagnetic fieldbetween the dispensing means and the collecting means. The electromagnetic field may be produced by, for example, means comprising at least one magnetic coil. The method according to this aspect of the invention may further comprise charging the moltenparticles. Charging the molten particles may be accomplished, for example, using a thermionic emission source or a tribocharging device. In one aspect, the dispensing means may be a gas atomizer. According to this aspect of the invention, the methodmay further comprise transferring heat from the molten particle. Transferring heat from the molten particles may be accomplished, for example, by gas conduction and/or convection and/or non-equilibrium plasma. In another aspect, the method of theinvention further comprises producing a second electromagnetic field. According to the invention, the method may further comprise transferring heat from the collecting means, which may be by a non-equilibrium plasma.
In another aspect, the present invention provides for a spray forming method comprising directing molten particles from a dispensing means to a collecting means by producing at least one of an electrostatic field or an electromagnetic fieldbetween the dispensing means and the collecting means, further comprising applying a rapid electrostatic charge to the molten particle, wherein the rapid electrostatic charge causes the molten particle to form at least one smaller molten particle. In aparticular aspect, the rapid electrostatic charge may be an arc discharge or an electron beam. In another aspect, the method of the invention may further comprise transferring heat from the molten particle comprising producing a non-equilibrium plasmathat transfers heat from the molten particle to a first heat sink, wherein the first heat sink is electrically charged or held at a potential. The non-equilibrium plasma may be a glow discharge or a cold corona discharge.
In another aspect, the invention is directed to an apparatus comprising a melt chamber comprising at least one orifice; a means for forcing a molten material through the at least one orifice in the melt chamber; and a means for applying a rapidelectrostatic charge to the molten material. The rapid electrostatic charge may be an arc discharge or en electron beam. The apparatus of the invention may further comprise a means for cooling the molten material. In a particular aspect, the means forcooling the molten material may comprise a first heat sink, wherein the first heat sink is electrically charged or held at a potential; and a means for transferring heat from the molten material to the first heat sink comprising a means for generating anon-equilibrium plasma. The non-equilibrium plasma may be a glow discharge or a cold corona discharge.
In another aspect, there is provided a method for atomizing a particle comprising producing a first molten particle; applying a rapid electrostatic charge to the first molten particle, wherein the rapid electrostatic charge causes the firstmolten particle to form at least one smaller second molten particle. According to the method of the invention, the first molten particle may be produced by melting a material in a melt chamber, and expelling the first molten particle through at leastone orifice in the melt chamber. The rapid electrostatic charge may be an arc discharge or en electron beam. The method of the invention may further comprise cooling the second molten particle by producing a non-equilibrium plasma that transfers heatfrom the second molten particle to a first heat sink, wherein the first heat sink is electrically charged or held at a potential. The non-equilibrium plasma may be a glow discharge or a cold corona discharge.
In another aspect, the invention provides for an apparatus for transferring heat between a first heat-transfer device and a workpiece comprising a first heat-transfer device, wherein the first heat-transfer device is electrically charged or heldat a potential, and wherein the first heat-transfer device is a heat sink or a heat source; a workpiece, wherein the workpiece is mechanically separate from the first heat-transfer device; and means for transferring heat between the workpiece and thefirst heat-transfer device comprising a means for generating a non-equilibrium plasma. The non-equilibrium plasma may be a glow discharge or a cold corona discharge. The apparatus of the invention may further comprise an external means for generatingor maintaining the non-equilibrium plasma. The external means for generating or maintaining the non-equilibrium plasma may be a thermionic emission, an RF electromagnetic radiation, an electromagnetic radiation, a magnetic field or an electron beam. The first heat-transfer device of the apparatus of the invention may comprise a plurality of heat-transfer devices. In a particular aspect, the apparatus of the invention may further comprise a second heat-transfer device that may be mechanically andelectrically separate from the first heat-transfer device, wherein the second heat-transfer device is a heat sink or a heat source, and wherein the potential between the first heat-transfer device and the second heat-transfer device produces anon-equilibrium plasma.
In another aspect is provided a method for transferring heat between a first heat-transfer device and a workpiece comprising producing a non-equilibrium plasma that transfers heat between the first heat-transfer device and the workpiece, whereinthe first heat-transfer device is electrically charged or held at a potential, wherein the first heat-transfer device is mechanically separate from the workpiece, and wherein the first heat-transfer device is a heat sink or a heat source. Thenon-equilibrium plasma may be a glow discharge or a cold corona discharge. The method may further comprise generating or maintaining the non-equilibrium plasma via an external means. In an aspect, the external means for generating or maintaining thenon-equilibrium plasma comprises a thermionic emission, an RF electromagnetic radiation, an electromagnetic radiation, a magnetic field or an electron beam.
In another aspect, the invention provides for a preform produced by the methods of the invention. The preform of the invention may be a near net preform. There is also provided an article of manufacture produced by the method of the invention.
These and other aspects of the present invention will become more apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of an apparatus of the present invention wherein an electrostatic field directs and accelerates molten particles to a preform.
FIG. 2 is a view of an apparatus of the present invention wherein an electrostatic field directs and accelerates particles to produce a near net shape preform, and a non-equilibrium plasma controls the temperature of the molten particles.
FIG. 3 is a view of an apparatus of the present invention wherein an electromagnetic field directs and accelerates molten particles to a preform, a first non-equilibrium plasma controls the temperature of the molten particles, and a secondnon-equilibrium plasma controls the temperature of the preform.
FIG. 4 is a view of an apparatus of the present invention wherein an electromagnetic field directs and accelerates molten particles to control particle collisions and resultant particle growth, and a non-equilibrium plasma cools the moltenparticles to form a powder.
FIG. 5 is a graph showing deflection versus applied voltage for a molten tin particle, as described in Example 2.
FIG. 6 is a view of a non-equilibrium plasma heat transfer apparatus wherein the heat-transfer device and the electrode producing the non-equilibrium plasma are a single element and a dielectric fluid is used to transfer heat from theheat-transfer device to a large thermal mass.
FIG. 7 is a view of a non-equilibrium plasma heat transfer apparatus wherein the heat-transfer device and the electrode producing the non-equilibrium plasma are a single element and the heat-transfer device is coupled to a large thermal mass viaa heat pipe.
FIG. 8 is a view of a non-equilibrium plasma heat transfer apparatus that can be used to cool powders or small workpieces (e.g., molten particles or preforms) in a vacuum.
FIG. 9 is a view of a non-equilibrium plasma heat transfer apparatus wherein the heat-transfer device and the electrode producing the non-equilibrium plasma are separate elements.
FIG. 10 is a view of an apparatus wherein a vacuum and pressure chamber serves as the dispensing means (e.g., melt chamber) for a molten material, pulsed pressure in the head space above the molten material produces molten particles through aplurality of nozzles at the base of the dispensing means, and rapid electrostatic charging is applied as the molten particles exit the nozzles to produce smaller molten particles.
FIG. 11 is a view of an apparatus wherein a flow control rod in a dispensing means (e.g., melt chamber) is manipulated to produce molten particles, and rapid electrostatic charging is applied as the molten particles exit the nozzle to producesmaller molten particles.
FIG. 12 is a view of multiple electrostatically induced atomizations wherein a droplet is atomized to form a plurality of smaller droplets which are further atomized to form a plurality of still smaller droplets. FIG. 14 is a photograph of thedroplets shown in FIG. 12.
FIG. 13 is a graph showing how primary atomized droplets are not sensitive to high voltage levels or electrode gaps once a critical value is reached for a particular geometry.
FIG. 14 is a photograph showing primary, secondary and tertiary droplets produced from the experiment in Example 5. FIG. 14 is a photograph of the droplets schematically drawn in FIG. 12.
FIG. 15 shows an apparatus used for liquid metal flow against the direction of gravity. FIG. 15A is a schematic illustration of FIG. 15.
FIGS. 16 and 17 show drops and droplets collected from an exemplary series of experiments described in Example 4. For each figure, the larger drops (upper portion of the figure) are those collected during the control experiments, and the smallerdroplets (lower portion of the figure) are those collected during experiments using an electrostatic field according to the invention.
FIGS. 18-25 show various views of a section of CPVC pipe, placed in the assembly of the apparatus of the invention in such a way as to surround the extractor ring and its supporting arm, permitting substantially higher potential differencesbetween nozzle and extractor before arcing and voltage breakdown. FIGS. 18, 19 and 20 show consecutive frames of the atomization of liquid metal against gravity without any applied mechanical force other than that due to the head of liquid in thereservoir. FIG. 18A is a schematic illustration of FIG. 18.
FIG. 26 shows twin electrode melting as the source for the molten metal for electrostatic atomizing.
FIG. 27 shows electron beam melting as the source for the molten metal for electrostatic atomizing in vacuum.
FIG. 28 shows electron beam cold hearth melting as the source for molten metal for electrostatic atomizing in vacuum.
FIG. 29 shows ESR/CIG melting as the source for the molten metal for electrostatic atomizing in vacuum.
FIG. 30 shows the atomized powder being collected in the bottom of the atomizing chamber.
FIG. 31 shows electrostatically atomized powder being collected as a solid preform after the powder is cooled via a non-equilibrium plasma.
FIG. 32 shows electrostatically atomized powder being collected in a can, where the can is transferred into a smaller chamber without breaking the vacuum. In the smaller chamber, the lid may welded to the can prior to hot working to a finalproduct.
FIG. 33 shows the production of a solid ingot in a mold from a powder produced by electrostatic atomization.
FIG. 34 shows three stages of electrostatic atomizing using plasma and one stage of electrostatic steering of the atomized powder.
FIG. 35 is a schematic diagram of the experimental set-up described in Example 5 for heat transfer using non-equilibrium plasmas.
FIG. 36 is an enlarged schematic diagram showing the dimensions of Blocks A and B described in FIG. 35.
FIG. 37 is a graph showing the temperature decay in air from Block A with and without the non-equilibrium plasma in atmospheric pressure, where the gap between the blocks was 1.5 inches, and the voltage applied for the non-equilibrium plasmas was51 keV, and Block A was in -ve potential.
FIG. 38 is a graph showing the temperature decay in air from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 1.5 inches, and the voltage applied for the non-equilibriumplasmas was 0.7 keV with a current maintained at 20 mA, and Block A was in -ve potential.
FIG. 39 is a graph showing the temperature decay in air from Block A with the non-equilibrium plasma (changing polarity of Block A) and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 1.5inches, and the voltage applied for the non-equilibrium plasmas was 0.6 and 0.8 keV with a current maintained at 20 mA.
FIG. 40 is a graph showing the temperature decay in air from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 4 inches, and the voltage applied for the non-equilibriumplasmas was about 0.7 keV with a current maintained at 20 mA, where Block A was at a -ve potential.
FIG. 41 is a graph showing the temperature decay in argon from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 4 inches, and the voltage applied for the non-equilibriumplasmas was 0.6 to 0.9 keV with a current maintained at 20 mA.
FIG. 42 is a graph showing the temperature decay in helium from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 4 inches, and the voltage applied for the non-equilibriumplasmas was 0.6 to 0.7 keV with a current maintained at 20 mA, where Block A was at a -ve potential.
FIG. 43 is a graph showing the temperature decay in air from Block A at various current with the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 4 inches, and the voltage applied for thenon-equilibrium plasmas was 0.5 to 1 keV with a current at 10 mA, 15 mA or 20 mA, where Block A was at a -ve potential.
FIG. 44 is a graph showing the temperature decay in air from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-2 Torr, where the gap between the blocks was 4 inches, and the voltage applied for the non-equilibriumplasmas was 1.2 to 1.6 keV with a current at 20 mA, where Block A was at a -ve potential.
FIGS. 45A-B are graphs showing the argon control and plasma experimental data and numerical simulation results (p.about.1E-1 Torr) for the modeling of the experimental data set presented in FIG. 39. Control and non-equilibrium plasma curves areseparated into two graphs to make the curve fit presentation clearer. FIG. 45A shows argon without plasma and shows the experimental and model results. FIG. 45B shows argon in the presence of a non-equilibrium plasma and shows the experimental andmodel results. The .gamma. factor necessary to relate the two model curves is .gamma.=10.5.
FIGS. 46A-B are schematic drawings of nozzle and extractor ring by a side view (FIG. 46A) and a view looking up through the extractor ring toward the nozzle (FIG. 46B).
FIG. 47 shows the profiles of electric field pendent drops, where the electric field increases from left to right.
FIG. 48 is a graph wherein the line with squares shows the limiting charge according to the Rayleigh Criterion, and the line with circles shows the calculated charge applied to a primary drop using measured voltage and the geometry of the drop. Though the graph shows that the primary drop should have been atomized into 4 to 6 times, some charge may have escaped to the environment or with the secondary droplets.
FIG. 49 is a schematic diagram of the experimental set-up described in Example 6 for heat transfer using non-equilibrium plasmas.
FIG. 50 is an enlarged schematic diagram showing the dimensions of Blocks A and B described in FIG. 49.
FIG. 51 is a graph showing the temperature decay in air from Block A with and without the non-equilibrium plasma in atmospheric pressure, where the gap between the blocks was 1.5 inches, and the voltage applied for the non-equilibrium plasmas was51 keV, and Block A was in -ve potential.
FIG. 52 is a graph showing the temperature decay in air from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 1.5 inches, and the voltage applied for the non-equilibriumplasmas was 0.7 keV with a current maintained at 20 mA, and Block A was in -ve potential.
FIG. 53 is a graph showing the temperature decay in air from Block A with the non-equilibrium plasma (changing polarity of Block A) and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 1.5inches, and the voltage applied for the non-equilibrium plasmas was 0.6 and 0.8 keV with a current maintained at 20 mA.
FIG. 54 is a graph showing the temperature decay in air from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 4 inches, and the voltage applied for the non-equilibriumplasmas was about 0.7 keV with a current maintained at 20 mA, where Block A was at a -ve potential.
FIG. 55 is a graph showing the temperature decay in argon from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 4 inches, and the voltage applied for the non-equilibriumplasmas was 0.6 to 0.9 keV with a current maintained at 20 mA.
FIG. 56 is a graph showing the temperature decay in helium from Block A with and without the non-equilibrium plasma at a pressure of 10.sup.-1 Torr, where the gap between the blocks was 4 inches, and the voltage applied for the non-equilibriumplasmas was 0.6 to 0.7 keV with a current maintained at 20 mA, where Block A was at a -ve potential.
FIG. 57 is a graph showing the temperature decay in air block-A in plasma and without plasma at pressure 10.sup.-2 Torr, gap between blocks was 4", and the voltage applied for plasma: 1:2 to 1.5 kev, current 20 mA.
FIG. 58 is a graph showing the results for the modeling of the experimental data set presented in FIG. 53 relating to argon and without plasma.
FIG. 59 is a graph showing the results for the modeling of the experimental data set presented in FIG. 53 relating to argon and with plasma.
FIG. 60 is a graph showing the comparison of with/without plasma for (Gamma)=10 in Example 7.
FIG. 61 is a graph showing how primary atomized droplets are not sensitive to high voltage levels or electrode gaps once a critical value is reached for a particular geometry.
FIG. 62 is a photograph showing primary, secondary and tertiary droplets produced from the experiment in Example 8.
FIGS. 63-64 are tables illustrating two sets of experimental data for liquid wood's metal atomization.
FIGS. 65-70 and FIGS. 74-76 are pictures illustrating a piece of CPVD pipe placed in such a way as to surround the extractor ring and its supporting arm.
FIGS. 71-72 are pictures illustrating drops and droplets collected in example 8.
FIG. 73 and FIGS. 77-79 are pictures illustrating an apparatus used for example 8.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides methods and apparatus for enhancing spray forming for the production of solid workpieces, known as preforms, and for powders. It has surprisingly been found that the amount or yield of powder collected during sprayforming can be controlled to an unexpectedly high degree by using an electrostatic and/or electromagnetic field to direct the trajectory of particles in the spray forming process. Additionally, the speed and/or direction of the particles can becontrolled to produce a solid workpiece using an electrostatic and/or electromagnetic field. Using an electrostatic and/or electromagnetic field, the particles can be directed to various areas of the preform at various times during the spray formingprocess to produce shapes. Using an electrostatic and/or electromagnetic field, particle size and trajectory can be controlled to avoid particle collisions, and the resulting growth in particle size that occurs when particles collide, or to causeparticle collisions if larger particle size is desired for any purpose. Using an electrostatic and/or electromagnetic field, the particles can be directed to areas where heat can be added or removed from the particles to control the macrostructure ofthe preform or powder being produced. The shape of the electrostatic and/or electromagnetic field can also be manipulated to produce near net shapes by directing where particles build up to form the preform at various times during the process. Sprayforming using an electrostatic field and/or an electromagnetic field can enhance the yield of the process as well as improve (and control) the density of the resulting preform.
The present invention describes methods and apparatus using electrostatic fields and/or electromagnetic fields for selectively controlling the yield, quality or density of solid workpieces (preforms) and powders produced by spray forming. Surprisingly, the methods and apparatus of the present invention have been unexpectedly found to provide enhanced yields of 95-99%, and unexpectedly provide workpieces that have a density that is 11-14% greater than the density of conventionally-formedworkpieces.
Preferably, the methods and apparatus of the present invention comprise a source of molten particles; a means for collecting the molten particles; and a means for directing the molten particles from the source of molten particles to the means forcollecting the molten particles.
The molten particles can be metallic or non-metallic. The term "metallic" includes metals and alloys, including, for example, iron, cobalt, nickel, aluminum, hafnium, zinc, titanium, niobium, zirconium, tin, copper, tungsten, molybdenum,tantalum, magnesium, stainless steels, bronze, brass, lithium alloys and nickel/cobalt based superalloys.
The source of molten particles may also be referred to herein as a "dispensing means." The dispensing means can be any known in the art including, for example, a container, an atomizer, a grinder, or other means of producing and/or dispensing themolten particles. The dispensing means is generally electrically insulated. Preferably, the dispensing means is a gas atomizing means. Any gas atomizing means known in the art may be used as the dispensing means in the present invention.
The acceleration, speed and/or direction of the molten particles can be manipulated and controlled by an electrostatic field and/or an electromagnetic field. The term "electrostatic field" can refer to a single electrostatic field or a pluralityof electrostatic fields. The term "electromagnetic field" can refer to a single electromagnetic field or a plurality of electromagnetic fields.
The means for collecting the molten particles may be referred to herein as a "collecting means." Generally, the collecting means is electrically insulated. For spray forming powders, the collecting means can be a hopper or other container. Thecontainer may comprise a lid and a mechanism for closing the lid. The collecting means may have a geometric shape, including, for example, a near net shape. Preferably, the distance between the dispensing means and the collecting means is from about 10cm to about 250 cm, more preferably, from about 20 cm to about 100 cm, and even more preferably, from about 25 cm to about 75 cm.
The invention may further comprise means for charging the molten particles before and/or after they leave the dispensing means. The means for charging the molten particles may comprise, for example, a thermionic emission source, a tribochargingdevice, or the like.
In one embodiment, an electrostatic field is produced between the dispensing means and the collecting means by connecting the collecting means to the positive or negative polarity of a high voltage DC power supply and by grounding the dispensingmeans. Preferably a positive polarity is used. Generally, the high voltage DC power supply is between about 4 kV and about 250 kV; more preferably, between about 8 kV and about 125 kV; and even more preferably between about 12 kV and about 100 kV. Themolten particles may be induction charged by the electric field. The induction charge causes the molten particles to move along the electrostatic field lines, thereby controlling the speed and direction of the molten particles and directing the moltenparticles from the dispensing means to the collecting means.
In another embodiment, an electrostatic field is produced between the dispensing means and the collecting means by connecting the dispensing means to the positive or negative polarity of a high voltage DC power supply and by grounding thecollecting means. Preferably, a positive polarity is used. By connecting the dispensing means to the positive or negative polarity of a high voltage DC power supply, the molten particles become electrically charged. The electrostatic field causes theelectrically charged molten particles to move along the electrostatic field lines, thereby controlling the speed and direction of the molten particles and directing the molten particles from the dispensing means to the collecting means.
The apparatus can further comprise a high voltage DC power supply and one or more electrodes that are placed between the dispensing means and the collecting means to shape the electrostatic field between the dispensing means and the collectingmeans. The electrostatic field then directs the molten particles to the collecting means.
The apparatus can also comprise a plurality of high voltage DC power supplies each attached to one or more electrodes that are placed between the dispensing means and the collecting means that change the shape of the electrostatic field betweenthe dispensing means and the collecting means in a time dependant manner to direct the molten particles to specific areas or points on the collecting means. This embodiment can produce near net shapes.
In another embodiment, an electromagnetic field is produced between the dispensing means and the collecting means by placing a magnetic coil between the dispensing means and the collecting means. The magnetic coil is connected to a power supply. The molten particles leaving the dispensing means are directed by the electromagnetic field to the collecting means. Preferably, the magnetic coil is capable of moving so that it can direct the molten particles to specific areas or points on thecollecting means. The molten particles can be directed to produce, for example, near net shapes.
In another embodiment, a plurality of magnetic coils can be placed between the dispensing means and the collecting means. The electromagnetic fields that are produced by the plurality of magnetic coils, which are singly or multiply energized todifferent magnetic field intensities, direct the molten particles to specific areas or points on the collecting means. The molten particles can be directed to produce, for example, near net shapes.
The embodiments of the invention presented in the following figures are for purposes of illustration only, and are not intended to limit the scope of the invention or the appended claims.
In FIG. 1, a dispensing means 201 produces molten particles 202, and an electrostatic field 203 is produced between the dispensing means 201 and the collecting means 204. The electrostatic field 203 charges the molten particles 202, which thencauses the molten particles 202 to accelerate toward the collecting means 204. The acceleration causes the solid workpiece (preform) 205 to build up on the collecting means 204 with a minimum of over-spray and bounce-off, thereby enhancing the yield ofthe process. The process can also enhance the density of the resulting solid workpiece (preform) 205. As shown in FIG. 1, the electric field is preferably intensified in the area where the molten particles 202 leave the dispensing means 201. Theinventors have unexpectedly discovered that the electrostatic field is most intense and compressed at the point just after the molten droplet leaves the nozzle. Surprisingly, pulling a droplet apart works for water, but does not work for liquid metal. To atomize a liquid metal, the inventors have discovered compressing the liquid or molten metal droplets.
In FIG. 2, a dispensing means 201 produces charged molten particles 202, and an electrostatic field 203 is produced between the dispensing means 201 and the shaped collecting means 206 to accelerate the charged molten particles 202 toward theshaped collecting means 206. The acceleration and directional control of the charged molten particles 202 enhances the density of the solid workpiece, and produces a near net shape solid workpiece 207. Optionally, a non-equilibrium plasma 24 is createdin the path of the molten particles 202 between two heat sink electrodes 209 which are connected to an outside thermal mass 210 by a dielectric liquid which flows through pipes 211 by the motive force provided by pumps 212. The arrangement between theheat sink electrodes 209 and the outside thermal mass 210 allows heat to be removed from the molten particles 202. The non-equilibrium plasma 24 between the heat sinks 209 is produced, for example, by means of an AC glow discharge or a corona discharge. The non-equilibrium plasma 24 transfers heat from the molten particles 202 to the two heat sink electrodes 209 which transfer the heat to the outside thermal mass 210.
In FIG. 3, a dispensing means 201 produces charged molten particles 202, and an electromagnetic field 213 is produced by a magnetic coil 214 which directs the molten particles 202 towards the collecting means 204. This directional control of themolten particles 202 can reduce over-spray, thereby enhancing the yield of the spray forming process. The invention can also enhance the density of the solid workpiece 205. Optionally, a non-equilibrium plasma 24 is created in the path of the moltenparticles 202 between two heat sink electrodes 209 which are connected to an outside thermal mass 210 by a dielectric liquid that flows through pipes 211 by the motive force provided by pumps 212. The arrangement between the heat sink electrodes 209 andthe outside thermal mass 210 allows heat to be removed from the molten particles 202. The non-equilibrium plasma 24 between the heat sink electrodes 209 is produced, for example, by means of an AC glow discharge or a corona discharge. Thenon-equilibrium plasma 24 transfers heat to the outside thermal mass 210. The non-equilibrium plasma 24 extends from the heat sink electrodes 209 into the path of the molten particles 202 and to the electrically grounded solid workpiece 205 and thecollecting means 204. In this embodiment heat is transferred from the molten particles 202, the solid workpiece 205 and the collecting means 204 by the non-equilibrium plasma 24 which allows heat to be transferred to the heat sink electrodes 209 whichtransfer the heat to the outside thermal mass 210.
In FIG. 4, a dispensing means 201 produces charged molten particles 202, and an electromagnetic field 213 produced by a magnetic coil 214 directs the molten particles 202 to spread out, thereby reducing the probability of their collision, andhence the formation of larger molten particles and larger powder particles. Optionally, a non-equilibrium plasma 24 is created in the path of the molten particles 202 between two heat sink electrodes 209 that are connected to the outside thermal mass210 by a dielectric fluid which flows through pipes 211 by the motive force provided by pumps 212. The arrangement between the heat sink electrodes 209 and the outside thermal mass 210 allows heat to be removed from the molten particles 202. A secondelectromagnetic field 216 produced by a magnetic coil 217 directs the cooled powder 218 to facilitate collection in the container 219 which is automatically closed by a mechanism 220 that attaches a lid 221 The entire powder manufacturing process can becarried out in a full or partial vacuum to reduce or eliminate contamination of the powder by chemical interaction with gases.
The present invention may also optionally comprise a heat sink placed between the dispensing means and the collecting means; a means for transferring heat from the molten particles to the heat sink to control the temperature of the moltenparticles once they have been ejected from the dispensing means; and a means for removing heat from the collecting means. The apparatus can comprise a means for transferring heat from the molten particles to the heat sink to control the temperature ofthe molten particles once they have been ejected from the dispensing means. The means for transferring heat can be gas conduction and/or convection. In addition to or in place of gas conduction and/or convection, another means for transferring heat canbe a non-equilibrium plasma.
The present invention also provides non-equilibrium plasmas for transferring heat between a heat-transfer device and a workpiece. In preferred embodiments, the non-equilibrium plasma is used for removing heat from molten particles after they aredispensed and/or electrostatically atomized, but before they are collected either as a solid workpiece or as a powder.
A class of plasmas known as non-equilibrium (NE) plasmas is produced when the temperature of the electrons in the gas exceeds the temperature of the neutral particles and large ions in the gas by at least 100%. Since the thermal conductivity ofnon-equilibrium plasmas depends on the electron temperature, the non-equilibrium plasmas will exhibit a high thermal conductivity. Since the temperature of neutral particles and large ions, which account for more than 99.9% of the mass present, is low,the overall heat content of the non-equilibrium plasma is low. Non-equilibrium plasmas used for heat transfer can be generated under very high and very low pressure conditions using gases which are inert or benign to the material(s) (e.g., the moltenparticles of the present invention) involved in the heat transfer. Thus, non-equilibrium plasmas can be used to add or remove heat from a workpiece without the undesirable mechanical, thermal, or chemical effects associated with plasmas in local thermalequilibrium.
The present invention also describes methods and apparatus for heat transfer between a heat-transfer device and a workpiece (e.g., molten particles and preforms) using non-equilibrium plasmas. Non-equilibrium plasmas eliminate the need formechanical contact between the workpiece and the heat-transfer device. There are many applications in which mechanical contact between the heat sink and the workpiece is not physically possible without undesirable damage to or chemical contamination ofthe workpiece, including, for example, spray forming, casting and other processes which use molten or non-solid substrate states.
In a preferred embodiment of the present invention, heat transfer is accomplished using non-equilibrium plasmas wherein the neutral and heavy ions have a temperature less than about 1000 K, preferably less than about 800 K, and more preferablyless than about 600 K. Since non-equilibrium plasmas are produced when the temperature of the electrons exceeds the temperature of the neutral particles and large ions by at least 100%, the electrons preferably have a corresponding temperature of atleast about 100 K, more preferably in excess of about 2000 K.
"Heat-transfer device," as used herein, refers to a heat sink or a heat source. "Heat source" refers to the object that is becoming colder, i.e., supplying the heat. "Heat sink" refers to the object that is becoming warmer, i.e., accepting theheat. It will be appreciated that the same object can function as a heat source and as a heat sink, depending upon the temperature variation in the other object, e.g., the workpiece, during the spray forming process. Accordingly, by means of theinvention it is possible to closely control the cooling (and heating) rate of the workpiece as a whole, as well as individual parts or sub-parts of the workpiece, and thereby to control those properties of the workpiece or parts thereof which are knownto be affected by cooling or heating rate.
In the present invention, the heat-transfer device or heat-transfer device electrode can be electrically charged or held at a potential. "Heat sink electrode" refers to the electrical potential source and the heat sink when they are integratedinto a single object. "Heat source electrode" refers to the electrical potential source and the heat source when they are integrated into a single object. "Heat-transfer device electrode" is used to refer to either a "heat sink electrode" or a "heatsource electrode." "Being held at a potential" refers to a DC offset voltage upon which an AC waveform may be superimposed.
The distance between the heat-transfer device or heat-transfer device electrode and the workpiece and the voltage applied to the heat-transfer device or heat-transfer device electrode and/or the workpiece is selected to create a non-equilibriumplasma between the workpiece and the heat-transfer device or heat-transfer device electrode to provide heat transfer. The non-equilibrium plasma is in contact with the heat-transfer device or heat-transfer device electrode and the workpiece, while theworkpiece is not in mechanical contact with the heat-transfer device or heat-transfer device electrode. The heat-transfer device or heat-transfer device electrode and the workpiece may be electrically connected, preferably through wires and a highvoltage power supply.
Preferably, the heat-transfer device and the electrode producing the non-equilibrium plasma are a single element, e.g., "a heat-transfer device electrode." An alternative embodiment uses a charged electrode to produce the non-equilibrium plasmaand a mechanically separate heat-transfer device, which is grounded or charged to about half the opposite potential of the electrode producing the non-equilibrium plasma. For example, the electrode may have a voltage of about 25,000 to about 150,000volts to produce the non-equilibrium plasma, while the heat-transfer device has a voltage about half the voltage of the electrode, such as from greater than about 0 to less than about 75,000 volts. It will be appreciated in this regard that the minimumgenerally desirable voltage of the heat transfer device will be that voltage which is required to be applied to effect in the workpiece the desired temperature, and so may approach 0, while the maximum generally desirable voltage will be about one-halfthat of the electrode. Preferably, the electrode and the heat-transfer device are not electrically connected.
Generally, the workpiece is electrically grounded or held at a potential opposite to the potential of the heat-transfer device or heat-transfer device electrode by a high voltage power supply. An object held at the opposite potential is one witha positive DC voltage applied to it when the other electrode is negative or vice versa. Opposite potentials are used to create the field strength required to produce a plasma. The distance between the workpiece and the heat-transfer device orheat-transfer device electrode is from about 10 cm to about 250 cm, more preferably, from about 20 cm to about 100 cm, and even more preferably, from about 25 cm to about 75 cm. Generally, the electrical potential or voltage between the workpiece andthe heat-transfer device or heat-transfer device electrode is from about 25,000 to about 150,000 volts DC, or from about 25,000 to about 150,000 volts AC.
The electrical potential applied between the workpiece and the heat-transfer device or heat-transfer device electrode produces a non-equilibrium plasma having a desired thermal conductivity. The non-equilibrium plasma is preferably a glowdischarge or a cold corona discharge. Alternatively, radio frequency signals, microwave signals or radiation can be used to produce the non-equilibrium plasmas. The thermal conductivity of the non-equilibrium plasma is generally about 2-10 timesgreater than the thermal conductivity of helium, preferably, about 5-10 times greater, and more preferably, about 8-10 times greater, and may exceed 10 times greater.
The workpiece can be any workpiece known in the art, including metals and non-metals. As used herein, "workpiece" refers to and includes a single workpiece or a plurality of workpieces. Nonlimiting examples of workpieces according to theinvention include powders and/or preforms produced by spray forming. The workpiece can be a plurality of workpieces having an average diameter of about 0.1 to about 10 cm. The workpiece can be a material or a section or portion of a material thatrequires a high rate of cooling to control solidification, thereby controlling grain structure and other metallurgical properties, such as, but not limited to, articles for gas turbine engines, including, for example, airfoils, blades, discs and blisks. Preferably, the workpiece is a molten particle or preform, as described herein.
The workpiece can be stationary or can move or pass through the non-equilibrium plasma. A dispensing means, as described herein, can be used to move or pass the workpiece through the non-equilibrium plasma. After the workpiece moves or passesthrough the non-equilibrium plasma, it can be captured or accumulated in any collecting means known in the art, as described herein.
The heat-transfer device or heat-transfer device electrode is connected to a thermal mass which allows heat to be added or removed from the workpiece by the non-equilibrium plasma. Heat can be transferred from the heat-transfer device to thethermal mass by any method known in the art. Preferably, the thermal mass will be a large thermal mass. A large thermal mass is one which can accept or donate a significant amount of thermal energy with only a small change in temperature. Heat can betransferred from the heat-transfer device to the large thermal mass by heat transfer means including, for example, a dielectric fluid, a heat pipe, a thermally conductive metal, a thermally conductive ceramic and the like. Dielectric fluids include, forexample, silicon, mineral oil and the like. Conductive metals include, for example, copper, aluminum, brass, silver, gold and the like. Conductive ceramics include, for example, mullites, steatites and other ceramic forms. For example, a dielectricliquid can be circulated through the heat-transfer device or heat-transfer device electrode through pipes by a pump that is used to move heat between the heat-transfer device or heat-transfer device electrode and the large thermal mass to keep thetemperature of the heat-transfer device or heat-transfer device electrode constant during the heat transfer process. In another embodiment, the heat-transfer device or heat-transfer device electrode can comprise a heat pipe to transfer heat between theheat-transfer device or heat-transfer device electrode and the large thermal mass to keep the temperature of the heat-transfer device or heat-transfer device electrode constant during the heat transfer process.
As used herein, the term "heat-transfer device" or "heat-transfer device electrode" can include a single heat-transfer device or heat-transfer device electrode or a plurality of heat-transfer devices or heat-transfer device electrodes that may ormay not be mechanically and/or electrically separate. For example, a plurality of heat-transfer devices can be used, wherein each individual heat-transfer device is electrically connected to a high voltage power supply, such that the potential betweenthe plurality of heat-transfer devices produces a non-equilibrium plasma. The electrode, in conjunction with the voltage applied by the power supply and the field gradient within the geometry, produces the non-equilibrium plasma. When a plurality ofheat-transfer devices is used, the distance between the individual heat-transfer devices can be any desired distance, such as about 1 to about 2,500 mm, preferably about 1 to about 1,500 mm, and the voltage between the individual heat-transfer devicescan be any desired voltage, such as about 25,000 to about 150,000 volts DC or about 25,000 to about 150,000 volts AC.
When a plurality of heat-transfer devices is used, some of the heat-transfer devices can produce a potential equal to about half the potential that is being used to produce the non-equilibrium plasma, but having the opposite polarity. Forexample, if two heat-transfer devices are used, the voltage applied to the first heat-transfer device producing the non-equilibrium plasma can be AC, and the second heat-transfer device can be connected to a separate high voltage power supply thatproduces a potential equal to about half the potential that is being used by the first heat-transfer device to produce the non-equilibrium plasma, but having a negative or positive polarity. In another embodiment, if two heat-transfer devices are used,the voltage applied to the first heat-transfer device producing the non-equilibrium plasma can be AC, and the second heat-transfer device can be connected to a separate high voltage power supply to produce a potential equal to about half the AC potentialbeing used by the first heat-transfer device to produce the non-equilibrium plasma, but having a positive or negative DC polarity. In still other embodiments, when two heat-transfer devices are used, the voltage applied to the first heat-transfer deviceproducing the non-equilibrium plasma can be AC, and the second heat-transfer device can be connected to a separate high voltage power supply producing an AC potential equal to about half the potential that is being used by the first heat-transfer deviceto produce the non-equilibrium plasma, but being out of phase with the potential of the first heat-transfer device that is producing the non-equilibrium plasmas. Thus, for example, the phase difference between the AC potential in the first heat-transferdevice and the AC potential in the second heat-transfer device can be adjusted between about 1 degree and about 180 degrees, and is preferably about 180 degrees. In these embodiments, the voltages are preferably between about 5 kV and about 75 kV, morepreferably between about 10 kV and about 50 kV, most preferably between about 15 kV and about 25 kV. Although two heat-transfer devices have been exemplified, it will be appreciated by one skilled in the art that these principles may readily be appliedto more than two heat-transfer devices in view of the teachings herein.
In some cases, a chamber can be used to enclose or contain the workpiece, the dispensing means, the collecting means, the means for directing the molten particle, the heat-transfer device and the electrode or the heat-transfer device electrode,and the non-equilibrium plasma. Such a chamber can be used to regulate the gas species present and/or the pressure. For example, the chamber may be evacuated and completely or partially filled with an inert gas (e.g., argon or nitrogen), or vice versa,to achieve the desired final metallurgy, to control the oxidation of other non-metal materials being processed, and/or to prevent undesired chemical reactions during the processing of materials, such as oxidation and nitridation. In a preferredembodiment, the pressure in such an enclosed chamber is less than atmospheric pressure, preferably from about 0.1 to about 0.0001 torr, more preferably from about 0.01 to about 0.001 torr.
In some cases, the voltage between the heat-transfer device electrode and the workpiece may not be sufficient to initiate and/or maintain the non-equilibrium plasma. In such cases, an external means for generating and/or maintaining thenon-equilibrium plasma can be used. Alternatively, an external means for generating and/or maintaining the non-equilibrium plasma can be used instead of using the electrodes and/or heat-transfer device electrodes. The external means can maintain and/orelevate the temperature difference between the electrons and the neutral and heavy ions in the non-equilibrium plasma by supplying energy to the electrons. The external means can be any known in the art, including, for example, electron beams,thermionic emissions, RF electromagnetic radiation, electromagnetic radiation in the range of frequencies from soft ultraviolet to hard x-rays, or magnetic fields.
The embodiments of the invention in FIGS. 6-9 are for purposes of illustration only, and are not intended to limit the scope of the invention or claims. Although FIGS. 6-9 refer to a heat sink, one skilled in the art will appreciate from theteachings herein that the heat sink can be replaced with a heat source. In FIGS. 6-9, the workpiece 101 is preferably a molten particle or preform, as described herein.
In FIG. 6, the workpiece 101 is electrically grounded or held at a potential opposite to the potential of the heat sink or heat sink electrode 102 by a high voltage power supply 103 connected by wires 104. An electrical potential is appliedbetween the workpiece 101 and the heat sink or heat sink electrode 102 to produce a non-equilibrium plasma 24 having a desired thermal conductivity. In a preferred embodiment, a dielectric liquid 106 is circulated through the heat sink or heat sinkelectrode 102 through pipes 107 by a pump 108 that moves heat between the heat sink or heat sink electrode 102 and a large thermal mass 109 to keep the temperature of the heat sink or heat sink electrode 102 constant during the heat transfer process.
In FIG. 7, the workpiece 101 is electrically grounded or held at a potential opposite to the potential of the heat sink or heat sink electrode 102 by a high voltage power supply 103 connected by wires 104. An electrical potential is appliedbetween the workpiece 101 and the heat sink or heat sink electrode 102 to produce a non-equilibrium plasma 24 having the desired thermal conductivity. In a preferred embodiment, the heat sink electrode 102 comprises a heat pipe 110 which transfers heatbetween the heat source or sink electrode 102 and a large thermal mass 109 to keep the temperature of the heat sink or heat sink electrode 102 constant during the heat transfer process.
In FIG. 8, an AC electrical potential is applied between a first and second heat sink or heat sink electrode 102 by a high voltage power supply 103 connected by wires 104 to produce a non-equilibrium plasma 24 through which the workpieces 101 arepassed. The source of the workpieces 101 is the dispensing means 111 which may comprise a container, atomizer, grinder or other means of producing or dispensing the workpieces 101. A means for collecting the heated or cooled workpieces 101 is providedby the hopper 112 The dispensing means 111 is contained within a chamber 113 and a vacuum pump 114 connected to the chamber 113 by a pipe 107 which serves to reduce the pressure within the chamber 113. This pressure reduction within the chamber 113 isoften desirable to reduce or eliminate contamination by unwanted gasses and also serves to reduce the voltages required to produce the non-equilibrium plasma 24. In this embodiment, a dielectric liquid 106 is circulated through the heat sink or heatsink electrode 102 and through pipes 107 by pumps 108 that move heat between the heat sink or heat sink electrode 102 and a large thermal mass 109 to keep the temperature of the heat sinks or heat sink electrodes 102 constant during the heat transferprocess. In this embodiment, a plurality of electrically charged heat sinks or heat sink electrodes may also be used and they may be oriented perpendicular to the direction of movement of the workpiece.
In FIG. 9, the workpiece 101 is electrically grounded or held at a potential opposite to the potential of the electrode 115 by a high voltage power supply 103 connected by wires 104. An electrical DC potential is applied between the workpiece101 and the electrode 115 to produce a non-equilibrium plasma 24 having the desired thermal conductivity, and which impinges on the surfaces of the workpiece 101,the electrode 115 producing the non-equilibrium plasma 24 and the heat sink or heat sinkelectrode 102.In this embodiment, a dielectric liquid 106 is circulated through the heat sink or heat sink electrode 102 and through pipes 107 by a pump 108 that is used to move heat between the heat sink or heat sink electrode 102 and a large thermalmass 109 to keep the temperature of the heat source or sink electrode 102 constant during the heat transfer process. In this embodiment, the heat sink or heat sink electrode 102 is either grounded or held at a potential opposite to that of electrode 115producing the non-equilibrium plasma 24 and having approximately 50% of the potential applied to the electrode 115. The potential of the heat sink or heat sink electrode 102 is controlled by a high voltage power supply 103 which is connected to the heatsink or heat sink electrode 102 by a wire 104. In this case, the electrode 115 producing the non-equilibrium plasma 24 and the heat sink or heat sink electrode 102, which adds or removes heat, are two separate elements. Typically voltages in the rangeof 25,000 to 150,000 volts are applied to electrode 115 to produce the non-equilibrium plasma 24, while the potential of the heat sink or heat sink electrode 102 has a voltage about half the voltage of electrode 115, such as from greater than about 0 toless than about 75,000 volts. The minimum generally desirable voltage of the heat sink or heat sink electrode 102 will be that voltage which is required to be applied to effect in the workpiece the desired temperature, and so may approach 0, while themaximum generally desirable voltage will be about one-half that of electrode 115.
Heat transfer using non-equilibrium plasmas has a wide range of applications, including, for example, arc welding, Mig welding, Tig welding, laser welding, metal spraying of preforms and powders, powder manufacture, and other metal fabricationand manufacturing processes which require a high rate of cooling, such as solidification and grain structure control in the cooling of alloys, superalloy casts and welds. A surprising and unexpected aspect of the present invention, then, is the use ofelectron flow within a non-equilibrium plasma to transfer heat, which in aspects of the invention may be accomplished in a vacuum.
Preferably, the dispensing means of the present invention is an atomizing means. Atomization of molten particles using rapid electrostatic charging results in the rapid breakup of particles into smaller particles due to electrostatic repulsionforces. The production of small particles has a wide range of commercial and industrial applications, including, for example, powder production, spray forming and metal coating processes.
Advantages of the present atomization methods and apparatus over conventional gas atomization include, for example, that the present invention can be carried out in a vacuum so that chemical interactions with the molten material can be controlledor eliminated, and any voids in the solid workpiece (e.g., preform) produced by the present invention would collapse during subsequent working of the workpiece (e.g., preform) so that no defects would exist in the final product.
In one embodiment of the present invention, a high voltage DC power supply is used to rapidly electrostatically charge molten particles beyond the Rayleigh limit, such that the electrostatic forces within the particles exceed the surface tensionof the material and the particles break up into smaller particles. The "Rayleigh limit" is the maximum charge a droplet can sustain before the electrostatic repulsion forces overcome the surface tension. This rapid electrostatic charge can also be usedto further break up the particles resulting from the first rapid electrostatic charge. Thus, several size refinements using rapid electrostatic charging are possible. Preferably, electrostatic charging is applied one, two, three, four or more times torefine the particles to a desired size. The final size to which droplets can be atomized is based on the applied voltage, the starting diameter of the particle, the rate of charging of the particle, and the geometry of the electrostatic orelectromagnetic field present.
In exemplary processes of the present invention, a material is placed in a container and liquified. The material can be metallic or non-metallic. The container can have one or more nozzles or orifices through which the molten material can flow. The container may also be referred to herein as a "dispensing means" or "melt chamber." The inside diameter of the orifice is preferably about 0.1 mm to about 10 mm, more preferably, about 0.15 mm to about 2 mm, yet more preferably, about 0.15 mm toabout 0.3 mm, most preferably, about 0.15 mm. When the inside diameter of the orifice is less than about 0.1 mm, it is difficult to achieve a consistent flow of the liquid metal The size of the primary droplet(s) need not be minimized since the goal ofthe invention is not to achieve a liquid metal spray at the tip of the nozzle.
In one embodiment, the dispensing means is sealed so that a vacuum and/or pressure can be created. The molten material is forced or expelled through the orifice(s) by a positive pressure that is created in the head space above the moltenmaterial. The pressure in the head space can be increased and decreased (e.g., pulsed or oscillated) in a time dependant manner to cause molten particles to be formed at the orifice(s) due to the periodic interruption of flow of the molten material. When the particles are ejected from the orifice(s), they enter the particle formation and collection chamber. The particle formation and collection chamber is preferably sealed so that a vacuum or pressure can be created in the chamber and so that gasescannot contaminate the molten particles or final product.
The pressure in the head space above the molten material in the dispensing means is preferably equal to or less than pressure in the particle formation and collection chamber to prevent molten material from discharging from the orifice. Thepressure in the head space above the molten material in the dispensing means is preferably increased by about 1 to about 1,500 mm of mercury at a frequency of about 1 to about 500 Hz, more preferably about 2 to about 200 Hz to cause interrupted flow(e.g., pulsed flow or oscillated flow) of the molten material through the orifice(s). Any method of interrupting flow by, for example, creating a positive or negative pressure differential between the head space and the dispensing means, or byelectrical or mechanical means, may be used. This interrupted flow causes the molten particles to form. The molten particles formed at this point may be referred to herein as "primary molten particles" because they are the first particles formed in theprocess.
The primary molten particles can be charged in several ways. The molten particles can be rapidly charged by conduction charging in the orifice(s) (e.g., before being expelled from the orifice) or by an electrostatic discharge into the moltenparticles as the molten particles are expelled from the orifice(s), and/or after the molten particles are expelled from the orifice(s). Preferably, the primary molten particles are rapidly electrostatically charged. The rapid electrostatic charge canbe created by, for example, an arc discharge or an electron beam. As used herein, "rapid" is from about 1 to about 500 microseconds, preferably about 1 to about 100 microseconds, most preferably about 1 to about 50 microseconds. The rapid charging ofthe primary molten particles creates a plurality of secondary molten particles that have a uniform diameter of about 5 to about 2,500 microns, preferably about 5 to about 250 microns. The secondary molten particles can be used to produce solid preformsor powders, or to coat a substrate(s), as described herein.
In an alternative embodiment, a nozzle and a dispensing means are arranged so that a flow control rod is moved by a mechanical or electromechanical actuator to allow the molten material to flow out of the nozzle through an orifice(s). Preferably, the flow control rod is moved vertically by the mechanical or electromechanical actuator. Optionally, pressure or a vacuum can be applied in the dispensing means. The container can comprise one or a plurality of nozzles and flow controlrods. A high voltage power supply, capable of providing a voltage rise rate of at least 3 million volts per second, is connected to the nozzle by a conductor. Preferably, the voltage rise rate is about 100 to about 100 million volts/second, morepreferably from about 500 kV to about 50 million volts/second, even more preferably from about 1 million to about 30 million volts/second. The rise rate is the slope of the waveform where the x axis is time and the y axis is voltage. The high voltageis applied to the nozzle at a high rise rate by the power supply and conductor and is synchronized with the momentary retraction of the flow control rod by the mechanical or electromechanical actuator which causes a primary molten particle to form. Thehigh voltage applied at a high rise rate causes the rapid electrostatic charging of the primary molten particle which causes the primary molten particle to break up or atomize into smaller secondary molten particles due to electrostatic forces.
The embodiment in FIG. 10 describes an apparatus for producing small molten particles that can be collected as a solid or used to coat a substrate. The apparatus comprises a vacuum and pressure vessel 1 which serves as the dispensing means. Avacuum source 2 is connected by a pipe 4a to a valve 3a which is in turn connected to the vacuum and pressure vessel 1 by a tube 5a. A pressure source 6 is connected by a pipe 4b to a valve 3b which is in turn connected to vacuum and pressure vessel 1by a tube 5b. A computer 7 reads the temperature of the molten material 8 by a temperature sensor 9 which is connected to the computer 7 by wire 10a. The computer 7 reads the pressure in the vacuum and pressure vessel 1 by a pressure sensor 11a whichis connected to the computer by wire 10b. The induction heat sources 12 are connected to the computer 7 by wires 10c. The positive side of the high voltage power supply 13 is connected to an electrode 14a by an insulated wire 10d and the negative sideof the high voltage power supply 13 is connected to electrodes 14b by an insulated wire 10e which passes through a vacuum tight insulated connector 18 and wire 10f. A second vacuum source 21 is connected by a pipe 4c to a valve 3c which is connected tothe particle formation chamber 20 by a tube 5c and is connected to the computer 7 by wire 10g. A pressure sensor 11b is connected to the computer 7 by wire 10h. The high voltage power supply 13 is connected to the computer for control by wire 10i.
In use, when the system initially starts, the computer 7 senses the pressure in vacuum and pressure vessel 1 and in the particle formation chamber 20 by the pressure sensors 11a and 11b, respectively. The computer 7 then controls the evacuationof the particle formation chamber 20 by the valve 3c controlling the second vacuum source 21 to produce a pre-set partial pressure level specific to the material to be atomized, and controls the first vacuum source 2 and the pressure source 6 by valves3a and 3b, respectively, to maintain a partial pressure in the vacuum and pressure vessel 1 equal to that in the particle formation chamber 20. The pressure is varied from atmospheric pressure down to a lower pressure until the desired flow rate andresulting particle size is achieved.
The computer 7 then senses the temperature of the material 8 by the temperature sensor 9 and provides power to the induction heaters 12 by wires 10c until the material achieves the desired pre-set melt temperature which causes the material toliquefy. At this point, a normal atomization cycle begins.
Once the computer 7 senses that the pre-set melt temperature has been reached, a positive pressure burst is applied to the vacuum and pressure vessel 1 by the computer 7 opening the valve 3b to the pressure source 6 thereby forcing some of themolten material 8 through the orifices 15 to form the primary molten particles 16. The computer 7 then closes the valve 3b and momentarily opens valve 3c and/or valve 3a to equalize the pressure between the vacuum and pressure vessel 1 and the particleformation chamber 20 which stops the molten material 8 from flowing. The high voltage power supply 13 is then turned on by the computer 7 and a rapid charging of the primary molten material particles 16 by the electrical arcs 19 causes the electrostaticforces within the primary molten particles 16 to exceed the surface tension energy resulting in the formation of smaller secondary molten particles 17.
The secondary molten particles 17 will then pass through a non-equilibrium plasma 24 created by second electrodes 25 which each transfer the heat to the outside of the particle formation chamber 20 to heat exchangers 26. The resulting cooledatomized particles are then collected by the collecting means 22 either as a solid preform or as powder, depending on the amount of cooling provided by the non-equilibrium plasma 24.
The cycle will then begin again at the point where normal atomization begins. Throughout the process, the computer 7 senses the temperature of the material 8 by the temperature sensor 9 and provides power to the induction heater 12 by wires 10cto maintain the desired pre-set melt temperature to maintain the material as a liquid. At the end of the atomization cycle, the computer 7, via a wire 10j, opens a vent 23 which is connected to the particle formation chamber 20 by a pipe 4d and isconnected to the air outside the particle formation chamber 20, which causes the pressure within the particle formation chamber 20 to equalize with the outside air pressure. Thereafter, the particle formation chamber 20 can be opened to remove theproduct.
In FIG. 11, a nozzle 30 and a dispensing means 1 are arranged so that a flow control rod 27 is moved by a mechanical or electromechanical actuator 28 to allow the molten material 8 to flow out of the nozzle 30 through an orifice 15. A highvoltage power supply 13, capable of providing a high voltage rise rate, is connected to nozzle 30 by a conductor 31. The high voltage is applied to the nozzle 30 at a high rise rate by the power supply 13 and conductor 31 and is synchronized with themomentary retraction of the flow control rod 27 by the mechanical or electromechanical actuator 28 which causes a primary molten particle 16 to form. The high voltage applied at a high rise rate causes the rapid electrostatic charging of the primarymolten particle 16 which causes the primary molten particle 16 to break up or atomize into smaller secondary molten particles 17 due to electrostatic forces.
In FIG. 12, a nozzle 30 and dispensing means 1 are arranged so that the primary molten particle 16 exits the orifice 15. Thereafter, the electrode 14a releases an electrical arc 19 that causes the electrostatic forces within the primary moltenparticle 16 to exceed the surface tension energy, resulting in the formation of smaller secondary molten particles 17. Subsequently, another electrode 14b releases an electrical arc 19 that causes the electrostatic forces within the secondary moltenparticles 17 to exceed the surface tension energy, resulting in the formation of smaller tertiary molten particles 40. Thereafter, another electrode 14c releases an electrical arc 19 that causes the electrostatic forces within the tertiary moltenparticles 40 to exceed the surface tension energy, resulting in the formation of smaller quaternary molten particles 41.
The electrodes 14a, 14b, 14c are rings of varying diameters, according to the electric potentials applied. Generally, they have diameters of about 1 to about 20 centimeters, preferably about 5 to about 15 centimeters. The electrodes 14a, 14b,14c can be extractor, expansion or compression rings, preferably they are an expansion or compression ring. An expansion ring is generally a bare metal wire ring that is at an electric potential such that an attractive or expansive force is exerted onthe charged droplet(s). A compression ring is generally a metal wire ring coated with a dielectric material of varying thickness. When an electric potential is applied to the compression ring, an opposite charge is induced upon the surface of thedielectric material, forming a squeezing (or compressive) force upon the droplet(s).
Preferably, an extractor ring 80 is also used in the apparatus of the present invention. The extractor ring 80 is generally the ring closest to the nozzle 15 that encourages extraction of the primary drop 16 from the nozzle 15.
According to the invention, the atomization process is manipulated using the methods and apparatus of the invention to effect the production of smaller droplets. It has been found that the extractor ring, when used in accordance with theinvention as described herein plays a significant role in controlling and/or maximizing the division process. While not intending to be bound by any particular theory, the wire rings seem to permit some expansive (sucking) force to be applied upon thedroplet as it passes the ring plane, while PVC rings seem to permit a compressive force to be applied upon the droplets. The importance of maintaining the environment in the vicinity of the electrostatic field at a temperature above the melting point ofthe liquid metal cannot be over-emphasized. As the droplets become smaller their surface area to mass ratio increases and they cool more rapidly.
Referring to FIGS. 46A-B, the distance between the nozzle 803 and the extractor ring 804 is generally about 1 to about 50 millimeters. The diameter of the extractor ring 804 varies according to the voltages that are applied. The extractor ring804 will be at an electric potential less than the nozzle 803 to cause liquid to be pulled from or extracted from the nozzle 803.
A positive high voltage DC source connected to the liquid metal reservoir produces an electric field between the nozzle and the grounded collector cup. The force of the field produced, acting together with gravity, causes atomized droplets ofsimilar size to be collected. This phenomenon is called primary atomization.
The placement of an extractor ring between the nozzle and collector cup and concentric to the droplet path causes lateral forces to be applied to the droplet, which can produce successively smaller droplets. This phenomenon is called secondaryand tertiary atomization, as shown in FIGS. 12 and 14. It is preferred to maximize the number of tertiary droplets produced. FIG. 13 shows the weight of the droplets produced versus the gap between the nozzle and the extractor. This figure clearlyillustrates that once a critical value is reached, primary atomization is not sensitive to the high voltage potential applied, or to the distance between the nozzle and the extractor. Table 2 and Table 3 show the results of experiments using bare copperwire extractors with different ring diameters.
FIG. 14 shows evidence abstracted from the same experimental sample. All droplets were produced by the same experiment. The choice of solidified droplets P.sub.0 to P.sub.4 demonstrates the way in which the primary droplets are subdivided. Thechoice of solidified droplets S.sub.0 to S.sub.4 shows this phenomenon then repeats upon the secondary droplets to produce tertiary droplets such as solidified droplet T.sub.0. Droplets P.sub.4 and S.sub.4 appear severed, but they are whole, and dropletT.sub.0 seems large for its weight. Unfortunately, these apparent anomalies arise from lens distortion due to the scanning and copying processes involved in producing FIG. 14.
While not intending to be bound by any particular theory, the division of an initial liquid metal drop into smaller droplets seems to be the result of three separate processes. Consider a case in which a liquid metal drop is emitted in thedirection of gravity from the capillary nozzle of a positively-charged reservoir towards a grounded baseplate. Assume that the surrounding environment is sufficiently warm for the drop (or atomized droplets) to remain liquid. The size of the dropemitted depends directly upon the electric field applied to the reservoir. The drop will form at the nozzle in a manner shown in FIG. 47, the size of the drop being governed by the field applied up to a critical value. Thereafter, only the rate atwhich the drop leaves the capillary nozzle is affected by the field.
The possibility of liquid metal spray occurring directly from the nozzle tip can be eliminated because the aperture of the nozzle (preferably about 0.15 mm inside diameter) is too large to permit formation of a Taylor-cone upon the free surface. The basic phenomenon of a liquid film deformation is that the outward electric stress (.sigma..sub.E) has to overcome the stress (.sigma..sub.s) due to surface tension (i.e., .sigma..sub.E.gtoreq..sigma..sub.S). A charged drop begins to atomize when theapplied force is in excess of the Rayleigh limit q.sub.r =8.pi.(.epsilon..sub.0.T.r.sup.3).sup.1/2 where .epsilon..sub.0, T, and r are permissivity of free space, surface tension of a liquid, and drop radius, respectively. The downward force of gravitycombines with the electrostatic force to cause the drop to be ejected from the nozzle before sufficient charge can accumulate to constitute a force that can overcome the liquid metal surface tension forces. Liquid metals have high inter-molecularbinding energies and thus have high values of surface tension so that drops are not readily torn off from the apex, even at reasonable field strengths. Hence, sufficient charge can never be created upon the liquid metal surface at the nozzle aperture bya DC field to satisfy the Rayleigh Criterion.
Now consider a case in which the liquid metal drop is emitted from the reservoir in a manner similar to that described in the paragraph above, but in this case the drop passes through an extractor ring connected to ground, or to a negativepotential with respect to the droplet collector cup, and is positioned concentric to the nozzle center and slightly below the nozzle tip (e.g., within about 1 to about 2 centimeters). As the drop falls toward a position that is coplanar with the ringplane, the field intensity between the drop and the ring increases.
If the potential difference between the drop and the ring is large enough to impart sufficient charge upon the drop, then the Rayleigh Limit may be reached. As the drop continues to fall toward the ring plane, the Rayleigh limit is surpassed andhighly charged particles with small mass are ejected, since the electrostatic forces have exceeded the surface tension forces. These particles should be ejected at the surface of the drop where the electrostatic field is densest, and it can be estimatedthat up to 25% of the charge is carried away by the particles, leaving the majority of the mass of the drop remaining with a lesser charge. Since the charge remaining on this residual drop is less than that required to satisfy the Rayleigh Criterion, nofurther atomization will occur unless the drop is recharged by induction along its flight path (see FIG. 48).
Finally, a case similar to that described in the paragraph above can be considered, where some charge remains upon the residual drop. This drop can be equated with the primary drop described throughout the present invention (see FIGS. 12 and14). If this drop is permitted to pass through a ring shaped electrode of a type similar to the extractor ring situated at some distance between the capillary nozzle and the collector, and connected to ground or to a negative potential, then someelectrostatic force is exerted upon the drop as it passes through the vicinity of the ring plane. If this force is sufficient to cause distortion of the drop, then the middle of the drop may be constricted sufficiently that surface tension forces willact along a path of least resistance at the neck by forming two (or possibly more) secondary drops.
Thus, this process can be repeated as the droplets pass through other strategically placed rings. However, as the mass of the initial drop is subdivided, so the charge on each droplet is reduced also (i.e., the charge to mass ratio is reduced)and some charge is lost to the immediate environment due to leakage. The drops may regain some positive charge by induction as they pass down the electrostatic force field, but the charge effect will reduce with distance from the capillary nozzle, andthe effect will be further reduced as the rings through which the drops have already passed act to nullify the electrostatic field. Any droplets produced in this manner would be third stage, or tertiary drops.
Thus, the possibility exists for successive atomization of a drop of liquid metal by a DC. electric field provided that certain criteria are met.
One criterion is reducing the flow rate of the liquid metal by controlling the high voltage that is applied to the reservoir. This permits the drop a slower passage through the ring system and so maximizes the atomization effect.
Another criterion is positioning the ring electrodes with successively negative and positive potentials in sandwich fashion such that the drops are alternately atomized, and then recharged by induction. For example, a ring that is funnel-shapedmay be used to investigate whether exposing the liquid metal drop to an intense field for a longer period can increase the charge imparted by induction, and also whether such a funnel-shaped electrode, when connected to a polarity opposite to thatinduced upon the drop will permit greater atomization to occur. However, in this situation there has to be some trade-off between the drop's downward velocity and the potential applied to the funnel electrodes. Too high a charging voltage on theelectrode will retard the drop's ability to leave the nozzle with minimum mass, while too little voltage will produce a shorter flight time in the shearing field. To some extent these effects can be minimized by varying the positions of the ringelectrodes along the drop's flight path, and it is these effects that we are currently studying.
Another criterion is maintaining a heated flight path that is longer than previously employed in order to facilitate the layering of rings. This flight path should be maintained at a temperature which ensures that all constituents of theeutectic alloy remain liquid. Though the eutectic isotherm for pure Wood's Metal is 70.degree. C., that for a recycled alloy, where the relative constituency may have changed, may be considerably higher.
At some stage successive atomization will no longer occur. Intuitively, there may be a limiting size of drop which cannot be further subdivided by electrostatic shearing. As the drop becomes smaller, there is less opportunity for theelectrostatic forces to form a distorted shape which can then usurp the surface tension forces to help form smaller droplets because as the drop's mass becomes smaller there will be a tendency for the drop to `float` on the field rather than be severedby it.
Tables 2 and 3 in Example 3 indicate that a finite number of groups (ostensibly 3 or 4) containing drops of similar sizes resulted from each experimental sample. While examining FIG. 14, we can understand why this situation occurs. As thepartially charged drop falls through the ring electrodes, electrostatic shearing forces act upon the drop. However, imperfections in construction mean that the ring is not exactly concentric to the drop's flight path, therefore the electrostatic fieldintensity acting upon the drop is not totally uniform. The drop is not divided exactly in a manner of binary division. Instead, two or more droplets of unequal mass are produced from each drop that is emitted from the nozzle. This produces samplescontaining the grouping that we have witnessed so far. Our aim therefore is to provide an opportunity for sufficient successive atomizations to occur until the requisite particle size distribution is achieved.
In preferred embodiments, the atomization methods and apparatus further comprise non-equilibrium plasmas for removing heat from the molten particles after they are electrostatically atomized but before they are collected either as a solidworkpiece or as a powder. Alternatively, non-equilibrium plasmas can be used to remove heat from the molten particles after they are applied to a substrate. FIGS. 26-34 show various preferred embodiments. In particular, FIGS. 26-29 provide examples ofmethods of making a molten metal stream or droplets in a vacuum for atomizing, while FIGS. 30-34 provide examples of methods used to collect the atomized liquid metal in a vacuum. The atomization methods, electrostatic methods, and non-equilibriumplasmas described in FIGS. 26-34 are preferably those of the present invention, as described herein.
FIG. 26 shows twin electrode melting as the source for the molten metal for electrostatic atomizing. The vacuum chamber 501 surrounds the electrodes 503 and the atomizing source 505. Molten metal 504, either as droplets or a stream, falls fromthe electrodes 503 to the electrostatic atomizer 505. The atomized material 506 flows out of the atomizer 505 and into a collecting means (not shown), examples of which are described in FIGS. 30-34.
FIG. 27 shows electron beam melting as the source for the molten metal for electrostatic atomizing in vacuum. The vacuum chamber 501 surrounds the electron beam source 502, the electrode 503, the atomizing source 505 and the collector (notshown). Molten metal 504, either as a stream or droplets, falls from the electrode 503 to the electrostatic atomizer 505. The atomized material 506 flows from the electrostatic atomizer 505 into a collection means (not shown), examples of which aredescribed in FIGS. 30-34.
FIG. 28 shows electron beam cold hearth melting as the source for molten metal for electrostatic atomizing in vacuum. The vacuum chamber 501 surrounds the electron beam source 502, the electrode 503, the water-cooled copper cold hearth 507, theatomizing source 505, and the collection device (not shown). Molten metal 504, either as a stream or droplets, falls from the water-cooled copper cold hearth 507 to the electrostatic atomizer 505. The atomized material 506 flows from the electrostaticatomizer 505 into a collection means (not shown), examples of which are described in FIGS. 30-34.
FIG. 29 shows ESR/CIG melting as the source for the molten metal for electrostatic atomizing in vacuum. Alternatively, a VAR/CIG melt source may be used in place of the ESR/CIG melt source. The vacuum chamber 501 surrounds the melt source, theelectrostatic atomizer 505 and the collection device (not shown). The ESR/CIG melt source includes an electrode 503 and a water-cooled copper crucible 507. A molten slag 508 acts to melt the electrode 503 to form a molten metal pool 509. The moltenmetal 204, either as a stream or droplets, flows through the CIG nozzle 510, and falls into the electrostatic atomizer 505. The atomized material 506 flows from the electrostatic atomizer 505 into a collection means (not shown), examples of which aredescribed in FIGS. 30-34.
Throughout the description of FIGS. 26-34, the molten metal 504 is preferably atomized using the methods described herein.
FIG. 30 shows the atomized powder being collected in the bottom of the atomizing chamber. The vacuum chamber 501 contains a melting and atomizing means described in FIGS. 26-29. The stream or droplets of molten metal 504 from the melt sourcesdescribed in FIGS. 26-29 passes through the atomizing zone 511. The atomized material 506 is collected at the bottom of the chamber 512.
FIG. 31 shows electrostatically atomized powder being collected as a solid preform after the powder is cooled via a non-equilibrium plasma. The vacuum chamber 501 contains a melting and atomizing means described in FIGS. 26-29. The stream ordroplets of molten metal 504 from the melt sources described in FIGS. 26-29 passes through the atomizing zone 511. The atomized powder 514 passes through a non-equilibrium plasma 515 and is collected as a solid preform 516. The non-equilibrium plasma515 is generated by producing a potential difference between two electrodes 503 from a power source 517. The heat from the atomized powder 514 is conducted through the non-equilibrium plasma 515 and the electrode 503 into a dielectric heat transfermedium to a heat exchanger 518.
FIG. 32 shows electrostatically atomized powder being collected in a can, where the can is transferred into a smaller chamber without breaking the vacuum. In the smaller chamber, the lid may welded to the can prior to hot working to a finalproduct. The vacuum chamber 501 contains a melting and atomizing means described in FIGS. 26-29. The stream or droplets of molten metal 504 from the melt sources described in FIGS. 26-29 passes through the atomizing zone 511. The atomized powder 514is directed into a can 519 via the process described in FIG. 34. When the can 519 is sufficiently full of atomized powder 514, it is transferred in the chamber 520 and the chamber 520 is sealed by a vacuum lock 521. A lid can then be applied to thefilled atomized powder can and the can released to the atmosphere via a second lock 521B for thermomechanical processing.
FIG. 33 shows the production of a solid ingot in a mold from a powder produced by electrostatic atomization. The vacuum chamber 501 contains a melting and atomizing means described in FIGS. 26-29. The stream or droplets of molten metal 504 fromthe melt sources described in FIGS. 26-29 passes through the atomizing zone 511. The atomized powder 514 is collected in a mold 522 and the solid ingot 524 withdrawn from the mold 522. Power supplies 517 provide the potential difference to form anon-equilibrium plasma 515 emanating from the electrodes 503. Heat is conducted from the surface of the solidifying ingots 524 to the electrodes 503 which are cooled with a dielectric liquid. The liquid is passed through heat exchangers 518 andreturned to the electrodes 503.
FIG. 34 shows three stages of electrostatic atomizing using plasma and one stage of electrostatic steering of the atomized powder. The vacuum chamber 501 contains a melting and atomizing means described in FIGS. 26-29. The stream or droplets ofmolten metal 504 from the melt sources described in FIGS. 26-29 passes through the atomizing zone 511. The non-equilibrium plasma 515 for imparting the atomizing conditions is provided by the potential difference between the electrodes 503. Thepotential difference is supplied by a high-voltage power supply 517. The atomized material from the first stage 525 passes to the second atomizing stage, and atomized materials of smaller size from the second stage 526 pass to the third stage. Atomizedmaterials from the third stage 527 pass through the steering stage to be steered in a direction which depends on the potential between the electrodes 503. Power for these electrodes is supplied by power supply 517.
Using various features described above, it would be readily apparent to one of ordinary skill in the art that the following exemplary embodiments can be implemented. Of instance, in one embodiment, the present invention describes apparatuscomprising dispensing means, collecting means, and means for directing molten particles from the dispensing means to the collecting means comprising an electrostatic field and/or an electromagnetic field. | | | |